JP7284183B2 - Disposable 3D printer cartridge - Google Patents

Description

The present invention provides a disposable 3D printer cartridge according to the preamble of claim 1, a system consisting of a disposable 3D printer cartridge and an exposure device, for manufacturing an object composed of additional layers by insertion into the exposure device, and It relates to a process for manufacturing an object consisting of additional layers according to the preamble of claim 16 .

Additive manufacturing devices (3D printers) are used in an increasing number of industries. This is due to the fact that the complex shaping of the product is simplified or made possible for the first time compared to other manufacturing processes.

Additive manufacturing devices are also used in the medical field to manufacture objects with complex shapes. These objects include, for example, dental crowns, implants, and the like.

Problems arise when the objects produced by the additive manufacturing device have to meet high hygiene requirements, since the production takes place in open containers. The polymerizable liquid required for production is removed from the storage container. When using multiple liquids, the liquids are mixed in the open. Aseptic conditions during additive manufacturing are therefore difficult or impossible to adhere to. Additive manufacturing devices must also be thoroughly cleaned after each use to meet hygiene requirements.

The object is made from a polymerizable liquid. Unused polymerizable liquid is often disposed of or recycled. However, from an economic and hygienic point of view this procedure is disadvantageous.

The shortcomings of the prior art described above lead to the problem from which the present invention is based: to improve additive manufacturing so that objects can be manufactured under improved hygienic and economic conditions. Another object is to be able to process multi-component printing materials with short processing times for the production of objects composed of multiple layers.

This object is achieved by a disposable 3D printer cartridge for manufacturing an object composed of additional layers by inserting it into an exposure device, said cartridge:
- a first lower housing part,
- a second upper housing part that can be removed from the first housing part;
- a support platform forming the underside of the second housing part, wherein the object composed of additional layers can be arranged outside of the support platform during construction of the object; - a component corresponding to the base of the first housing part, the layer of the object being polymerizable on the inner surface of the component, the inner surface of the component having a non-stick coating; It is characterized by comprising a component.

Said cartridge is able to meet all the normal hygiene requirements imposed on objects manufactured with additional layers. This is of particular importance with regard to medical products. Such medical products include implants, dental prostheses or products of the chip industry that must achieve clean room class. All medical specifications for implants can be met. Said cartridge contains all the essential elements required for the manufacture of an object composed of additional layers, ie a three-dimensional article. All elements contained within the cartridge are properly sealed inside the cartridge and are only accessible during manufacture of the object. The cartridge is opened only by separating the second housing part from the first housing part.

By providing the components in the first housing part, the objects can be arranged in the cartridge with good protection. The components can be manufactured from materials customary in 3D printing. The component preferably includes a separation membrane made of a non-stick material from which the cured polymeric body layer can be easily removed. It is particularly preferred that the separation membrane consists of tetrafluoroethylene propylene (FEP). This is because this material has a non-stick effect on many polymeric resins. The resin is preferably curable by irradiation with a light source, especially a UV light source.

In one preferred embodiment of the invention, the first housing part is a container that is open at the top and receives the second housing part. Therefore, all elements of the second housing part are well protected by the first housing part while the cartridge is stored and sealed. Even during manufacture of the object after opening the cartridge, the first housing part surrounds the second housing part and protects the object from contamination and mechanical influences during manufacture.

In a particularly preferred embodiment of the invention, a liquid reservoir is formed on the second housing part, said liquid reservoir being filled with at least one polymerizable liquid. The cartridge is ready to use filled with the required amount and type of at least one polymerizable liquid, said at least one liquid being stored in the cartridge for a long time and well protected. Therefore, only the amount of liquid mixture required for the construction of the object can be activated. Unsanitary repeated use of the cartridge is prevented by such liquid volume limitations.

In a further embodiment of the invention, an insertion space is provided on the second housing part, into which a liquid reservoir can be inserted. An external liquid reservoir can be inserted into the insertion space. An external liquid reservoir can be, for example, a blister bag that is punctured before use. The provision of the insertion space makes the cartridge suitable for a wide variety of liquids and particularly flexible in its application.

The liquid reservoir expediently has at least first and second receiving spaces filled with the first and second polymerizable liquids, the lower ends of said receiving spaces being open into the mixing chamber, the supporting platform comprising: Interrupted by at least one inlet channel in fluid communication with the mixing chamber, said inlet channel opens into the first lower housing part to allow transfer of the liquid mixture into the lower housing part. These elements of the liquid reservoir allow the liquid to be mixed just prior to processing the liquid and extruded as a finished mixture into the lower portion of the housing. In the lower housing part the components are completely covered with the liquid mixture. It is also conceivable to provide multiple inlet channels. This allows the polymerizable liquid to be transferred to the lower housing between the support platform and the component in an unmixed or partially mixed state depending on the application.

The cartridge is expediently designed in one piece and has a predetermined breaking point at the transition from the first housing part to the second housing part. By breaking the predetermined breaking point, the cartridge is immediately ready for use without further preparation and the two housing parts can be inserted into the exposure device.

It is also conceivable that the cartridge is designed as two parts, the first and the second housing part being detachably connected to each other. Although this connection is detachable, it is sufficiently sealed so that the elements of the cartridge are well protected during storage.

In a particularly preferred embodiment of the invention, the first and second housing parts are connected by a telescopic connecting element in the region of the transition from the first housing part to the second housing part. Due to this connecting element the interior space between the first housing part and the second housing part remains closed from the environment even when the cartridge is opened and objects are being produced (printed) in the interior space. Up to The telescoping connecting element connects the two housing parts even if the two housing parts are pulled apart during printing. Preferably, the telescopic connecting element is a bellows attached to the edges of the two housing parts facing each other. The bellows can be longitudinally pulled apart while the second housing portion moves upwardly relative to the first housing portion.

In a further preferred embodiment of the invention, the outside of the base of the first housing part is covered with a first removable protective cover. The components are therefore well protected and are free only for irradiation by the light source if necessary.

It has been found to be advantageous if the upper part of the second housing part is covered with a second removable protective cover. As a result, the liquid reservoir, in particular its stopper or insertion space, is protected from contamination and damage while the cartridge is not inserted.

The liquid reservoir expediently has at least one plug by means of which the liquid can be expelled and the filling opening of the liquid reservoir can be closed. The plug allows the liquid space to be closed from above and the liquid to be completely removed from the liquid space.

The invention also preferably provides that the first housing part has a first holding element, by means of which the first housing part can be held on the exposure device, and by means of the first holding element It is characterized in that the component can be fixed on the exposure device. The first housing part is preferably connected to the first holding element by a fit. For example, the first holding element is a protrusion that can be pushed into a groove of the exposure device. The component is aligned or adjusted with respect to the support platform by pretensioning the component. In addition, pretensioning the component provides a flat printing surface, making it easier to remove the cured layer of the object from the component. After using the cartridge, the engagement allows the cartridge to be more easily removed from the exposure device.

Advantageously, the second housing part has a second holding element with which the second housing part can be held on the exposure device. A second housing part is secured to the lifting device by a second retaining element. A lifting device lifts the second housing part relative to the first housing part during construction of additional layers of the object. Like the first housing part, the second housing part is preferably retained on the lifting device by a fit. As a result, the second housing part can be fastened to the lifting device and removed from the lifting device just as quickly.

Another aspect of the invention relates to a system comprising a disposable 3D printer cartridge according to the above description and an exposure device into which the first and second housing parts can be inserted, the object comprising additional layers being on a support platform It can be manufactured between a first housing part and a second housing part. Therefore, the essential parts for manufacturing the object are contained in the cartridge. The light source necessary for curing the layers of the object is provided by the exposure device. The exposure device also comprises a lifting device with which the upper housing part can be lifted with respect to the lower housing part. The exposure device also comprises at least one plunger by means of which liquid can be expelled from the liquid reservoir into the lower housing part. The system allows hygienic production of objects composed of additional layers without contaminating the exposure device.

Another aspect of the invention relates to a disposable 3D printer cartridge for manufacturing an object composed of additional layers by insertion into an exposure device having components, wherein a liquid reservoir is formed on the cartridge, The liquid reservoir is filled with at least one polymerizable liquid or an insertion space is provided on the cartridge into which the liquid reservoir can be inserted and the cartridge has a support platform forming the underside of the cartridge. The object formed and composed of additional layers can be arranged outside the support platform. In this embodiment the cartridge consists only of the second housing part. Elements of the first housing part, in particular the open container and the components forming the base of the container, are part of the exposure device. This embodiment allows virgin liquid mixtures to be used to construct other objects with relatively low hygiene requirements. With a 3D printer, this embodiment can provide a homogeneous printing material by mixing the polymerizable liquid in the second housing part.

Another aspect of the invention relates to a process for manufacturing an object consisting of additional layers, said process comprising the following process steps:
- opening the disposable 3D printer cartridge according to the above description by separating the first lower housing part from the second upper housing part;
- fixing the first and second housing parts in the exposure device;
- pushing at least one polymerizable liquid from the second housing part into the first housing part with at least one plunger provided on the exposure device; and - curing the layer by exposure to light. progressively building up additional layers of the object by gradually increasing the distance between the first housing portion and the second housing portion each time.

By means of the above process, an object composed of additional layers can be produced while being protected within two housing parts. Contamination of the object by liquid filling or other process steps that are open to the environment is reliably avoided, since the upper housing part is already filled with the necessary liquid that can be cured by irradiation with light. . A cartridge is configured to be used only once to manufacture an object. Cartridges must be disposed of after use. Reuse of the cartridge, which also leads to contamination of the object, is thus prevented.

In a preferred embodiment of the present invention, the step of extruding at least one polymerizable liquid is performed completely prior to construction of the article, or is performed simultaneously and synchronously with construction of the layers of the article. In most cases, the at least one polymerizable liquid is first extruded into the lower housing portion used as the container. Preferably, the amount of liquid is just enough to form the object. However, if the mixed liquid has a short processing time and is to be processed immediately after entering the lower housing part, the liquid can be fed "just in time" into the lower housing part. It is advantageous to move. This means that partial feeding of polymerizable liquid is associated with progressive lifting of the upper housing part relative to the lower housing part.

Further advantages and features become apparent from the following description of two exemplary embodiments of the invention with reference to schematic drawings. Drawings are not drawn to scale.

1 is a longitudinal cross-sectional view of a first embodiment of a disposable 3D printer cartridge according to the present invention; FIG. FIG. 2 is a longitudinal cross-sectional view of a second embodiment of a disposable 3D printer cartridge according to the present invention; Figure 3 is a longitudinal section through the cartridge of Figure 1 after manufacturing an object composed of additional layers;

1 and 3 show a first embodiment of a disposable 3D printer cartridge, generally designated 11. FIG.

Cartridge 11 comprises a first lower housing portion 13 and a second upper housing portion 15 . The two housing parts 13, 15 must be separated from each other before the cartridge 11 is inserted into an exposure device (not shown). Cartridge 11 is hermetically sealed until used in an exposure device and is therefore particularly suitable for use under sterile conditions.

The two housing parts 13, 15 are connected to each other at a predetermined breaking point 17 and can be separated at this point to make the cartridge 11 ready for use. The predetermined breaking point 17 can be provided on the cartridge 11 manufactured as one piece. Cartridge 11 is preferably manufactured by injection molding. If the first and second housing parts 13, 15 are manufactured separately, they are detachably connected to each other, thereby sealing the contents of the cartridge. As shown in FIGS. 1 and 2, the lower housing part 13 is an open-topped container in which the upper housing part 15 is received.

According to a first embodiment of the cartridge (FIGS. 1, 3), a liquid reservoir 19a is formed on the second upper housing part 15. As shown in FIG. In the drawing an embodiment of a liquid reservoir 19a is shown, in which three different liquids 21a, 21b, 21c polymerizable on exposure to light are filled in the receiving space 23 of the liquid reservoir 19a.

The liquids 21a, 21b, 21c can be forced by the plug 25 into a mixing chamber 27 where they can be activated by mixing them. A static mixer can be provided in the mixing chamber 27 for homogeneously mixing the liquid 21 . Liquids 21 a , 21 b , 21 b can enter the lower housing part 13 through inlet channels 29 . The lower housing part 13 can thus function as a reservoir for the activated liquid mixture.

The underside of the upper housing part 15 is formed with a support platform 31 . An object 33 to be manufactured is arranged on the outside of the support platform 31 facing the lower housing part 13 .

The base of the lower housing part 13 is designed as a component 35 on which an object 33 can be superimposed. The component 35, or at least its inner surface facing the second housing part 15, has a non-stick coating. As a result, layers polymerized by exposure to light can be removed from component 35 as each layer is cured.

It has been found to be particularly advantageous to provide both the support platform 31 and the component 35 for the cartridge 11 . Object 33 is constructed as a layer between support platform 31 and the component. The object is thus manufactured in the cartridge 11 between the lower housing part 13 and the upper housing part 15 by a so-called bottom-up process. This means that the object layer to be built up is built up on the base of the lower housing part 13 rather than on the liquid surface (resin surface). Since the object is constructed by moving the upper housing part 15 upward and away from the base of the lower housing part 13, a small amount of mixed liquid (resin) 37 is present in the lower housing part 13. is sufficient. The base or component 35 must be covered with resin so that the resin can always flow between the base and the object 33 to build up the layers. Since the light source is located below the base, the base or component 35 must be light transmissive. Light source 35 is preferably a UV light source.

In order to allow the upper housing part 15 to move away from the lower housing part 13 during manufacture of the object 33, both housing parts 13, 15 can be fixed within the exposure device. For this purpose, a first holding element 39 is formed on the first lower housing part 13 and a second holding element 41 is formed on the second upper housing part 41 .

A first holding element 39 can be used to hold the lower housing part 13 in the exposure device so that the component 35 is pressed upwards by the light source 43 and pretensioned. Pre-tensioning the component 35 aligns or adjusts the component 35 with respect to the support platform 31 . Accurate alignment of components 35 allows objects 33 with very tight dimensional tolerances. Pretensioning can also facilitate removal of each cured layer from the component 35 after exposure to light.

Component 35 preferably comprises a separation membrane. The separation membrane is composed of a non-stick material and the cured polymeric layer of the object can be easily removed from this separation membrane. It is particularly preferred that the separation membrane consists of tetrafluoroethylene propylene (FEP). This is because this material has a non-stick effect with many photocurable resins.

A second holding element 41 can be used to fix the upper housing part 15 onto the exposure device. The exposure device comprises a lifting device by means of which the second housing part 15 can preferably be permanently lifted and lowered again with respect to the first housing part. Each time a layer of object 33 is cured by irradiation in the vicinity of the light source, upper housing part 15 is lifted by one layer thickness after object 33 is removed from component 35 .

The exposure device also has at least one plunger with which the plug 25 can be depressed, thereby forcing the liquids 21a, 21b, 21c out of the receiving space 23 and into the lower housing part 13. can be done.

The objects are placed in particularly hygienic conditions in that the cartridge 11 is only opened during the production of the objects 33, the required amount of liquid 21a, 21b, 21c has already been added and the objects are produced in the cartridge 11. can be manufactured under Cartridge 11 is provided as a disposable cartridge. After manufacture of object 33 and removal of object 33 from cartridge 11, cartridge 11 is disposed of.

The two housing parts 13, 15 are each provided with first and second removable protective covers 45, 47 on the open side. As a result, the cartridge 11 is hermetically sealed until use. The first protective cover 45 and the second protective cover 47 must be removed before use. A first protective cover 45 protects the component 35 and a second protective cover 47 protects the liquid reservoir 19a or the plug 25 so that they are not accidentally pressed or contaminated prior to use. disappears.

Figure 2 shows a second embodiment of the cartridge 11, in which the liquid reservoir 19b is not part of the second housing part 15 but can be inserted into an insertion space 49 provided on the second housing part 15. They are separate parts. As a result, the cartridge 11 according to this second embodiment can be used with a separately available liquid reservoir.

The manufacture of the object 33 by the cartridge 11 is carried out in the following process steps: First, the cartridge 11 is broken by twisting the upper housing part 15 with respect to the lower housing part 13 to break predetermined breaking points 17 . Open. As a result, the two housing parts 13, 15 which were already hermetically connected are separated from each other. By removing the first protective cover 45 and the second protective cover 47 from the housing parts 13, 15, the cartridge 11 is ready for use.

When inserting the cartridge 11 into the exposure device, the upper housing part 15 remains received in the lower housing part 13 and is lifted only slightly. Thus, support platform 31 and component 35 remain protected during insertion of cartridge 11 . By lifting, the second holding element is connected to the lifting device so that the upper housing part 15 can be connected to the lifting device. The lower housing part 13 is connected to the exposure device by a first holding element 39 . In this way component 35 is aligned by light source 43 .

The liquid 21a, 21b, 21c (photocurable resin) is then forced out of the liquid reservoir 19a or 19b into the lower housing part 13 using a plunger. The plunger is provided on the exposure device and can be adapted to the number of receiving spaces 23 and the required displacement path of the plug 25 .

Once the mixed liquid 37 covers the component 35, additional formation of the layer of object 33 begins. After curing the layer by irradiation with the light source 43, the upper housing part 15 is lifted from the lower housing part 13 by one layer thickness by means of a lifting device. The distance between the two housing parts 13, 15 thus increases during construction of the object.

It is also conceivable for the liquid reservoir 19a or 19b to be emptied synchronously with the formation of the layers rather than before the formation of the layers. This only makes sense if the liquids are mixed just prior to processing.

The disposable 3D printer cartridge 11 has extremely high hygiene standards as it is opened only immediately before the manufacture of the object 33 and is hermetically sealed before that. Furthermore, the disposable 3D printer cartridge 11 contains only the amount of curable liquid 21a, 21b, 21c necessary to manufacture the object 33. FIG. Cartridge 11 is disposed of after manufacture of object 33 so that no further cleaning is required. A new, hygienically perfect cartridge 11 is therefore always used for manufacturing the object 33 .

11 Disposable 3D printer cartridge 13 First lower housing part 15 Second upper housing part 17 Predetermined breaking points 19a, 19b Liquid reservoirs 21a, 21b, 21c Polymerizable liquid 23 Receiving space 25 Stopper 27 Mixing chamber 29 Inlet channel 31 support platform 33 object 35 composed of additional layers component 37 mixed liquid 39 first retaining element 41 second retaining element 43 light source 45 first protective cover 47 second protective cover 49 insertion space

Claims (15)

A disposable 3D printer cartridge (11) for manufacturing an object (33) composed of additional layers by insertion into an exposure device, said cartridge (11) containing at least one polymerizable liquid (21a, 21b, 21c) or the polymerizable liquid can be filled in the cartridge (11),
Said cartridge (11) is:
- a first lower housing part (13),
- a second upper housing part (15) detachable from said first lower housing part (13),
- a support platform (31) forming the underside of said second upper housing part (15), said object (33) being composed of additional layers, during construction of said object, said support platform (31) and - a component (35) corresponding to the base of said first lower housing part (13), which supports a layer of said object (33). A component (35) capable of being polymerized on an inner surface of said component (35), said inner surface of said component (35) having a non-stick coating.
In a cartridge (11) comprising
Said second upper housing part (15) is separable from said first lower housing part (13) in order to open said cartridge for manufacturing said object (33) and said first Cartridge (11), characterized in that the lower housing part (13) is a container which is open at the top and receives said second upper housing part (15). a liquid reservoir (19a) is formed on said second upper housing part (15) and is filled with said at least one polymerizable liquid (21a, 21b, 21c),
The cartridge of Claim 1. 3. Cartridge according to claim 1 or 2, characterized in that an insertion space (49) is provided on the second upper housing part (15) into which a liquid reservoir (19b) can be inserted. . said liquid reservoir (19a) having at least first and second receiving spaces (23) filled with a first polymerizable liquid (21a) and a second polymerizable liquid (21b);
the lower end of said receiving space is open into the mixing chamber (27),
said support platform (31) is interrupted by at least one inlet channel (29) in fluid communication with said mixing chamber (27);
Said inlet channel (29) opens into said first lower housing part (13) thereby transferring a liquid mixture (37) into said first lower housing part (13). 4. A cartridge according to claim 2 or 3, characterized in that it is capable of said cartridge (11) is designed in one piece and has a predetermined breaking point (17) at the transition from said first lower housing part (13) to said second upper housing part (15); The cartridge according to any one of claims 1 to 4, characterized by: 4. Characterized in that the cartridge (11) is designed as two parts, the first lower housing part (13) and the second upper housing part (15) being detachably connected to each other. 5. The cartridge according to any one of 1 to 4. Said first lower housing part (13) and said second upper housing part (15) form a transition from said first lower housing part (13) to said second upper housing part (15). Cartridge according to any one of the preceding claims, characterized in that in the region of the parts they are connected by telescopic connecting elements. 8. The method according to any one of the preceding claims, characterized in that the outside of the base of the first lower housing part (13) is covered with a first removable protective cover (45). cartridge. A cartridge according to any one of the preceding claims, characterized in that the upper part of said second upper housing part (15) is covered with a second removable protective cover (47). Said liquid reservoirs (19a, 19b) have at least one plug (25) by means of which said liquids (21a, 21b, 21c) can be expelled and said liquid reservoirs (19a, 19b) ) can be closed. Said first lower housing part (13) has a first retaining element (39) by means of which said first lower housing part (13) is held onto said exposure device. 11. A cartridge according to any one of the preceding claims, characterized in that said first holding element ( 39 ) allows said component (35) to be fixed on said exposure device. Said second upper housing part (15) has a second holding element (41) by means of which said second upper housing part (15) is placed on said exposure device. The cartridge according to any one of claims 1 to 11, characterized in that it can hold Comprising a disposable 3D printer cartridge (11) according to any one of claims 1 to 12 and an exposure device into which a first lower housing part (13) and a second upper housing part (15) can be inserted. a system,
A system, wherein an object (33) composed of additional layers can be manufactured between said first lower housing part (13) and said second upper housing part (15) on a support platform (31). A process for manufacturing an object (33) consisting of additional layers, comprising the following process steps:
- opening the disposable 3D printer cartridge (11) according to any one of claims 1 to 12 by separating the first lower housing part (13) from the second upper housing part (15); step,
- fixing said first lower housing part (13) and said second upper housing part (15) in an exposure device;
- pushing at least one polymerizable liquid (21a, 21b, 21c) from said second upper housing part (15) into said first lower housing part using at least one plunger provided on said exposure device; (13), and - each time the layer is cured by exposure to light, the distance between said first lower housing part (13) and said second upper housing part (15) is increased. A process comprising progressively configuring said additional layers of said object (33) by increments. Said step of extruding said at least one polymerizable liquid (21a, 21b, 21c) may be performed completely prior to construction of said object (33) or synchronized during construction of said layers of said object (33). 15. A process according to claim 14, characterized in that it is performed systematically.

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